Titan Aero extruder assembly

grabcad

2018.03.05 - Updated the idler arm to V3.7.1- A slight modification to the part, mostly just to smoothen some surfaces to make the .stl less crappier.- Widened the top of the support structure for the press bearing enclosure. Now it's clearly visible where to separate the support from the part.It's the extruder assembly on my 3D printer. I use the E3D Titan extruder for a while, and as it's far from being perfect, I made some improvements on the original design.1. Extruder lever (idler)The factory part is a plastic lever simply sliding on the stepper motor axle. That caused a lot of problems, since it was a bit tight so my stepper motor's temperature suddenly raised up to 90-95°C during operation. So I started to design my own idler, running on two ball bearings, which proved to be useful as the motor temperatures instantly dropped down to ~45°C.In this assembly, the lever is totally independent from the stepper axle (Actually, this is not necessary, I did it because my new 0.9° stepper motor came with such short axle that I couldn't mount the idler the same way. This way it might be a bit less comfortable to assemble the extruder, but aligning the hot end centerline with the idler arm is easier, since they are attached to the same part.I also changed the simple bearing to a grooved one, because I found the filament to have the tendency to wander sideways.2. When assembling the Titan, you have to set the tooth clearance by positioning the whole extruder body, which is a pain in the ass in multiple ways. 1st, it's quite difficult to find the right position, simply because tightening the screws alters the position a bit, so you have to calculate with that, and 2nd, you have to do it every time you reassemble it. Finally, 3rd, because it's pretty much impossible to assemble the extruder in the same position twice in a row.So I designed an excenter part that makes the fine tuning of tooth clearance quite easy, and once it is set, you can assemble the extruder in the exact same position as many times as you want.3. I also changed to the Hexagon A0 hot end from the E3D ones. It has an amazing heat break (The best I've met so far) , so needs less cooling. Actually once I forgot to switch on the hot end fan, and it still completed a one-hour print.I've uploaded stl files in the STL folder. The excenter is straightforward, you can just print it. The extruder lever is more complicated, so I made 3 versions of it. The 1st has no support, so you have to take care of it. The 2nd one assumes 0.25mm nozzle, the 3rd the 0.30mm nozzle. The lever has to be printed with 0.1mm layer thickness. As for the material, the ColorFabb XT-CF20 carbon-filled filament proved to be the best so far.